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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

High-Speed, High-Temperature Finger Seal Test Evaluated

A finger seal, designed and fabricated by Honeywell Engines, Systems and Services, was tested at the NASA Glenn Research Center at surface speeds up to 1200 ft/s, air temperatures up to 1200 F, and pressures across the seal of 75 psid. These are the first test results obtained with NASA s new High-Temperature, High-Speed Turbine Seal Test Rig (see the photograph). The finger seal is an innovative design recently patented by AlliedSignal Engines, which has demonstrated considerably lower leakage than commonly used labyrinth seals and is considerably cheaper than brush seals. The cost to produce finger seals is estimated to be about half of the cost to produce brush seals. Replacing labyrinth seals with fingers seals at locations that have high-pressure drops in gas turbine engines, typically main engine and thrust seals, can reduce air leakage at each location by 50 percent or more. This directly results in a 0.7- to 1.4-percent reduction in specific fuel consumption and a 0.35- to 0.7-percent reduction in direct operating costs . Because the finger seal is a contacting seal, this testing was conducted to address concerns about its heat generation and life capability at the higher speeds and temperatures required for advanced engines. The test results showed that the seal leakage and wear performance are acceptable for advanced engines.

Proctor, Margaret P.↗
NASA NTRS2005

Work Began on Contracts for Radioisotope Power Conversion Technology Research and Development

NASA has had a history of successful space flight missions that depended on radioisotope-fueled power systems. These Radioisotope Power Systems (RPSs) converted the heat generated from the decay of radioisotope material into useful electrical power. An RPS is most attractive in applications where photovoltaics are not optimal, such as deep-space applications where the solar flux is too low or extended applications on planets such as Mars where the day/night cycle, settling of dust, and life requirements limit the usefulness of photovoltaics. NASA s Radioisotope Power Conversion Technology (RPCT) Program is developing next-generation power-conversion technologies that will enable future missions that have requirements that cannot be met by the two RPS flight systems currently being developed by the Department of Energy for NASA: the Multi-Mission Radioisotope Thermoelectric Generator and the Stirling Radioisotope Generator (SRG).

Wong, Wayne A.↗
NASA NTRS2005

Journal Bearing Analysis Suite Released for Planetary Gear System Evaluation

Planetary gear systems are an efficient means of achieving high reduction ratios with minimum space and weight. They are used in helicopter, aerospace, automobile, and many industrial applications. High-speed planetary gear systems will have significant dynamic loading and high heat generation. Hence, they need jet lubrication and associated cooling systems. For units operating in critical applications that necessitate high reliability and long life, that have very large torque loading, and that have downtime costs that are significantly greater than the initial cost, hydrodynamic journal bearings are a must. Computational and analytical tools are needed for sufficiently accurate modeling to facilitate optimal design of these systems. Sufficient physics is needed in the model to facilitate parametric studies of design conditions that enable optimal designs. The first transient journal bearing code to implement the Jacobsson-Floberg-Olsson boundary conditions, using a mass-conserving algorithm devised by Professor Emeritus Harold Elrod of Columbia University, was written by David E. Brewe of the U.S. Army at the NASA Lewis Research Center1 in 1983. Since then, new features and improved modifications have been built into the code by several contributors supported through Army and NASA funding via cooperative agreements with the University of Toledo (Professor Ted Keith, Jr., and Dr. Desikakary Vijayaraghavan) and National Research Council Programs (Dr. Vijayaraghavan). All this was conducted with the close consultation of Professor Elrod and the project management of David Brewe.

Brewe, David E.↗
NASA NTRS2006

Chromite-Plagioclase Assemblages as a New Shock Indicator; Implications for the Shock and Thermal Histories of Ordinary Chondrites

Chromite in ordinary chondrites (OC) can be used as a shock indicator. A survey of 76 equilibrated H, L and LL chondrites shows that unshocked chromite grains occur in equant, subhedral and rounded morphologies surrounded by silicate or intergrown with metallic Fe-Ni and/or troilite. Some unmelted chromite grains are fractured or crushed during whole-rock brecciation. Others are transected by opaque veins; the veins form when impacts cause localized heating of metal-troilite intergrowths above the Fe-FeS eutectic (988 C), mobilization of metal-troilite melts, and penetration of the melt into fractures in chromite grains. Chromite-plagioclase assemblages occur in nearly every shock-stage S3-S6 OC; the assemblages range in size from 20-300 microns and consist of 0.2-20-micron-size euhedral, subhedral, anhedral and rounded chromite grains surrounded by plagioclase or glass of plagioclase composition. Plagioclase has a low impedance to shock compression. Heat from shock-melted plagioclase caused adjacent chromite grains to melt; chromite grains crystallized from this melt. Those chromite grains in the assemblages that are completely surrounded by plagioclase are generally richer in Al2O3, than unmelted, matrix chromite grains in the same meteorite. Chromite veinlets (typically 0.5-2 microns thick and 10-300 microns long) occur typically in the vicinity of chromite-plagioclase assemblages. The veinlets formed from chromite-plagioclase melts that were injected into fractures in neighboring silicate grains; chromite crystallized in the fractures and the residual plagioclase-rich melt continued to flow, eventually pooling to form plagioclase-rich melt pockets. Chromite-rich chondrules (consisting mainly of olivine, plagioclase-normative mesostasis, and 5-15 vol.% chromite) occur in many shocked OC and OC regolith breccias but they are absent from primitive type-3 OC. They may have formed by impact melting chromite, plagioclase and adjacent mafic silicates during higher-energy shock events. The melt was jetted from the impact site and formed droplets due to surface tension. Crystallization of these droplets may have commenced in flight, prior to landing on the parent-body surface. Chromite-plagioclase assemblages and chromite veinlets occur in 25 out of 25 shock-stage S1 OC of petrologic type 5 and 6 that I examined. Although these rocks contain unstrained olivine with sharp optical extinction, most possess other shock indicators such as extensive silicate darkening, numerous occurrences of metallic Cu, polycrystalline troilite, and opaque veins. It seems likely that these rocks were shocked to levels at least as high as shock-stage S3 and then annealed by heat generated during the shock event. During annealing, the olivine crystal lattices healed but other shock indicators survived. Published Ar-Ar age data for some SI OC indicate that many shock and annealing events occurred very early in the history of the parent asteroids. The common occurrence of shocked and annealed OC is consistent with collisions being a major mechanism responsible for metamorphosing OC.

Rubin, Alan E.↗
NASA NTRS2005

From H.G. Wells to Unmanned Planetary Exploration

The possibility of planetary exploration has been a dream of the human race since Galileo discovered the moons of Jupiter in 1610. Visual sightings of bodies entering Earth s atmosphere have been made by Earth s inhabitants over the centuries. Over time, the many meteor showers (Leonid, Perseid) have provided dramatic evidence of the intense heat generated by a body entering Earth s atmosphere at hypervelocity speeds. More recently (in 1908), few viewed the Tunguska meteor that impacted in Siberia, but the destructive power on the countryside was awesome.

Boyd, John W.↗
NASA NTRS2007

Living Together in Space: The International Space Station Internal Active Thermal Control System Issues and Solutions-Sustaining Engineering Activities at the Marshall Space Flight Center From 1998 to 2005

On board the International Space Station, heat generated by the crew and equipment is removed by the internal active thermal control system to maintain a comfortable working environment and prevent equipment overheating. Test facilities simulating the internal active thermal control system (IATCS) were constructed at the Marshall Space Flight Center as part of the sustaining engineering activities to address concerns related to operational issues, equipment capability, and reliability. A full-scale functional simulator of the Destiny lab module IATCS was constructed and activated prior to launch of Destiny in 2001. This facility simulates the flow and thermal characteristics of the flight system and has a similar control interface. A subscale simulator was built, and activated in 2000, with special attention to materials and proportions of wetted surfaces to address issues related to changes in fluid chemistry, material corrosion, and microbial activity. The flight issues that have arisen and the tests performed using the simulator facilities are discussed in detail. In addition, other test facilities at the MSFC have been used to perform specific tests related to IATCS issues. Future testing is discussed as well as potential modifications to the simulators to enhance their utility.

Wieland, P. O.↗
NASA NTRS2006

Brush Seal Arrangement for the RS-68 Turbopump Set

The nature of the RS-68 turbopumps requires that the hydrogen seals separating the pump from the turbine must have extremely low levels of leakage and be contained in small packages. Conventional seal technologies are not able to reasonably satisfy such design requirements. A review of experimental measurements and analysis publications suggests that brush seals are well suited for the design requirements. Brush seals are shown to have less leakage than conventional labyrinth and damper seals and have no adverse effects on the rotordynamics of the machine. The bulk-flow analysis presented by Hendricks et al. is used as a guideline to create a spreadsheet that provides mass flow through the seal and heat generated by the rubbing contact of the bristles on the shaft. The analysis is anchored to published data for LN2 and LH2 leakage tests. Finally, the analysis is used to design seals for both applications. It is observed that the most important analysis parameter is the thickness of the bristle pack and its relationship to seal clearance, lay angle and pressure drop.

Nunez, D.↗
NASA NTRS2007

Robustness of Modeling of Out-of-Service Gas Mechanical Face Seal

Gas lubricated mechanical face seal are ubiquitous in many high performance applications such as compressors and gas turbines. The literature contains various analyses of seals having orderly face patterns (radial taper, waves, spiral grooves, etc.). These are useful for design purposes and for performance predictions. However, seals returning from service (or from testing) inevitably contain wear tracks and warped faces that depart from the aforementioned orderly patterns. Questions then arise as to the heat generated at the interface, leakage rates, axial displacement and tilts, minimum film thickness, contact forces, etc. This work describes an analysis of seals that may inherit any (i.e., random) face pattern. A comprehensive computer code is developed, based upon the Newton- Raphson method, which solves for the equilibrium of the axial force and tilting moments that are generated by asperity contact and fluid film effects. A contact mechanics model is incorporated along with a finite volume method that solves the compressible Reynolds equation. Results are presented for a production seal that has sustained a testing cycle.

Green, Itzhak↗
NASA NTRS1989

High density associative memory

A multi-layered, thin-film, digital memory having associative recall. There is a first memory matrix and a second memory matrix. Each memory matrix comprises, a first layer comprising a plurality of electrically separated row conductors; a second layer comprising a plurality of electrically separated column conductors intersecting but electrically separated from the row conductors; and, a plurality of resistance elements electrically connected between the row condutors and the column conductors at respective intersections of the row conductors and the column conductors, each resistance element comprising, in series, a first resistor of sufficiently high ohmage to conduct a sensible element current therethrough with virtually no heat-generating power consumption when a low voltage as employed in thin-film applications is applied thereacross and a second resistor of sufficiently high ohmage to conduct no sensible current therethrough when a low voltage as employed in thin-film applications is applied thereacross, the second resistor having the quality of breaking down to create a short therethrough upon the application of a breakdown level voltage across the first and second resistors.

Moopenn, Alexander W.↗
NASA NTRS2008

Testing of SMA-enabled Active Chevron Prototypes under Representative Flow Conditions

Control of jet noise continues to be an important research topic. Exhaust-nozzle chevrons have been shown to reduce jet noise, but parametric effects are not well understood. Additionally, thrust loss due to chevrons at cruise suggests significant benefit from active chevrons. The focus of this study is development of an active chevron concept for the primary purpose of parametric studies for jet noise reduction in the laboratory and secondarily for technology development to leverage for full scale systems. The active chevron concept employed in this work consists of a laminated composite structure with embedded shape memory alloy (SMA) actuators, termed a SMA hybrid composite (SMAHC). SMA actuators are embedded on one side of the neutral axis of the structure such that thermal excitation, via joule heating, generates a moment and deflects the structure. The performance of two active chevron concepts is demonstrated in the presence of representative flow conditions. One of the concepts is shown to possess significant advantages for the proposed application and is selected for further development. Fabrication and design changes are described and shown to produce a chevron prototype that meets the performance objectives.

Turner, Travis L.↗
NASA NTRS2006

Thermal Imaging of Aerospace Battery Cells

Surface Thermal Profiles of Eagle Picher rabbit-ear 50Ah NiH2 and of Saft 40 Ah Li-ion cylindrical cells have been studied using ThermCAM S60 FLIR Systems. Popping Phenomenon in NiH2 cell is demonstrated Temperature gradient in NiH2 is slightly higher than normally considered, for example. Middle of stack to top or bottom is about 12.9 C compared to <7 C (may be due to passive cooling). Less than 1 C thermal gradient on the Li-Ion cell vessel surface. Significantly lower heat generation in Li-Ion cell compared to NiH2 cell. -May be due to a favorable charge method used for Li-Ion cell.

Shue, Jack↗
NASA NTRS2008

Deconvoluting the Friction Stir Weld Process for Optimizing Welds

In the friction stir welding process, the rotating surfaces of the pin and shoulder contact the weld metal and force a rotational flow within the weld metal. Heat, generated by the metal deformation as well as frictional slippage with the contact surface, softens the metal and makes it easier to deform. As in any thermo-mechanical processing of metal, the flow conditions are critical to the quality of the weld. For example, extrusion of metal from under the shoulder of an excessively hot weld may relax local pressure and result in wormhole defects. The trace of the weld joint in the wake of the weld may vary geometrically depending upon the flow streamlines around the tool with some geometry more vulnerable to loss of strength from joint contamination than others. The material flow path around the tool cannot be seen in real time during the weld. By using analytical "tools" based upon the principles of mathematics and physics, a weld model can be created to compute features that can be observed. By comparing the computed observations with actual data, the weld model can be validated or adjusted to get better agreement. Inputs to the model to predict weld structures and properties include: hot working properties ofthe metal, pin tool geometry, travel rate, rotation and plunge force. Since metals record their prior hot working history, the hot working conditions imparted during FSW can be quantified by interpreting the final microstructure. Variations in texture and grain size result from variations in the strain accommodated at a given strain rate and temperature. Microstructural data from a variety of FSWs has been correlated with prior marker studies to contribute to our understanding of the FSW process. Once this stage is reached, the weld modeling process can save significant development costs by reducing costly trial-and-error approaches to obtaining quality welds.

Schneider, Judy↗
NASA NTRS2008

Lidar System for Airborne Measurement of Clouds and Aerosols

A lidar system for measuring optical properties of clouds and aerosols at three wavelengths is depicted. The laser transmitter is based on a Nd:YVO4 laser crystal pumped by light coupled to the crystal via optical fibers from laser diodes that are located away from the crystal to aid in dissipating the heat generated in the diodes and their drive circuits. The output of the Nd:YVO4 crystal has a wavelength of 1064 nm, and is made to pass through frequency-doubling and frequency-tripling crystals. As a result, the net laser output is a collinear superposition of beams at wavelengths of 1064, 532, and 355 nm. The laser operates at a pulse-repetition rate of 5 kHz, emitting per-pulse energies of 50 microJ at 1064 nm, 25 microJ at 532 nm and 50 microJ at 355 nm. An important feature of this system is an integrating sphere located between the laser output and the laser beam expander lenses. The integrating sphere collects light scattered from the lenses. Three energy-monitor detectors are located at ports inside the integrating sphere. Each of these detectors is equipped with filters such that the laser output energy is measured independently for each wavelength. The laser output energy is measured on each pulse to enable the most accurate calibration possible. The 1064-nm and 532-nm photodetectors are, more specifically, single photon-counting modules (SPCMs). When used at 1064 nm, these detectors have approximately 3% quantum efficiency and low thermal noise (fewer than 200 counts per second). When used at 532 nm, the SPCMs have quantum efficiency of about 60%. The photodetector for the 355-nm channel is a photon-counting photomultiplier tube having a quantum efficiency of about 20%. The use of photon-counting detectors is made feasible by the low laser pulse energy. The main advantage of photon-counting is ease of inversion of data without need for complicated calibration schemes like those necessary for analog detectors. The disadvantage of photon-counting detectors is that they inherently have narrow dynamic ranges. However, by using photon-counting detectors along with a high-repetition rate laser, it is possible to obtain wide dynamic range through accumulation of counts over many pulses.

McGill, Matthew↗
NASA NTRS2009

Thermoelectric Devices Cool, Power Electronics

Nextreme Thermal Solutions Inc., based in Research Triangle Park, North Carolina, licensed thermoelectric technology from NASA s Jet Propulsion Laboratory. This has allowed the company to develop cutting edge, thin-film thermoelectric coolers that effective remove heat generated by increasingly powerful and tightly packed microchip components. These solid-state coolers are ideal solutions for applications like microprocessors, laser diodes, LEDs, and even potentially for cooling the human body. Nextreme s NASA technology has also enabled the invention of thermoelectric generators capable of powering technologies like medical implants and wireless sensor networks.

Source record↗
NASA NTRS2009

An Overview of Non-Metallic Brush Seal Technology

Non-metallic brush seals are ultra-low flow sealing elements ideal for low pressure differentials (<30 psid) and low temperature (typically <300 degF) applications. The compliant bristle pack of a non-metallic brush seal is advantageous in terms of sealing capability during transients. However, if not designed properly, the bristle pack compliance can be detrimental to the performance of the seal. GE GLobal Research has investigated the stiffness and heat generation properties of non-metallic brush seals made from Kevlar and Carbon Fiber. The presentation will review the progress made on the design points of the seals, as well as highlight some current commercial applications of the technology.

Ruggiero, Eric J.↗
NASA NTRS2011

Gear Mesh Loss-of-Lubrication Experiments and Analytical Simulation

An experimental program to determine the loss-of-lubrication (LOL) characteristics of spur gears in an aerospace simulation test facility has been completed. Tests were conducted using two different emergency lubricant types: (1) an oil mist system (two different misted lubricants) and (2) a grease injection system (two different grease types). Tests were conducted using a NASA Glenn test facility normally used for conducting contact fatigue. Tests were run at rotational speeds up to 10000 rpm using two different gear designs and two different gear materials. For the tests conducted using an air-oil misting system, a minimum lubricant injection rate was determined to permit the gear mesh to operate without failure for at least 1 hr. The tests allowed an elevated steady state temperature to be established. A basic 2-D heat transfer simulation has been developed to investigate temperatures of a simulated gear as a function of frictional behavior. The friction (heat generation source) between the meshing surfaces is related to the position in the meshing cycle, the load applied, and the amount of lubricant in the contact. Experimental conditions will be compared to those from the 2-D simulation.

Handschuh, Robert F.↗
NASA NTRS2011

Thermally Conductive Tape Based on Carbon Nanotube Arrays

To increase contact conductance between two mating surfaces, a conductive tape has been developed by growing dense arrays of carbon nanotubes (CNTs, graphite layers folded into cylinders) on both sides of a thermally conductive metallic foil. When the two mating surfaces are brought into contact with the conductive tape in between, the CNT arrays will adhere to the mating surface. The van der Waals force between the contacting tubes and the mating surface provides adhesion between the two mating surfaces. Even though the thermal contact conductance of a single tube-to-tube contact is small, the tremendous amount of CNTs on the surface leads to a very large overall contact conductance. Interface contact thermal resistance rises from the microroughness and the macroscopic non-planar quality of mating surfaces. When two surfaces come into contact with each other, the actual contact area may be much less than the total area of the surfaces. The real area of contact depends on the load, the surface roughness, and the elastic and inelastic properties of the surface. This issue is even more important at cryogenic temperatures, where materials become hard and brittle and vacuum is used, which prevents any gas conduction through the interstitial region. A typical approach to increase thermal contact conductance is to use thermally conducting epoxies or greases, which are not always compatible with vacuum conditions. In addition, the thermal conductivities of these compounds are often relatively low. The CNTs used in this approach can be metallic or semiconducting, depending on the folding angle and diameter. The electrical resistivity of multiwalled carbon nanotubes (MWCNTs) has been reported. MWCNTs can pass a current density and remain stable at high temperatures in air. The thermal conductivity of a MWCNT at room temperature is measured to be approximately 3,000 W/m-K, which is much larger than that of diamond. At room temperature, the thermal conductance of a 0.3 sq cm array of CNTs was measured to be as high as 10 W/K. The high thermal conductivity and the nanoscale size make CNTs ideal as thermal interface materials. The CNT-based thermal tape can be used for the thermal management of microelectronic packages and electronic systems. It also can be integrated with current device technology and packaging. The material would allow for an efficient method to manage excess heat generation without requiring any additional power. Lastly, the CNT tape can be used to enhance thermal contact conductance across two mating surfaces on some NASA missions.

Kashani, Ali↗
NASA NTRS2011

Developing Flexible, High Performance Polymers with Self-Healing Capabilities

Flexible, high performance polymers such as polyimides are often employed in aerospace applications. They typically find uses in areas where improved physical characteristics such as fire resistance, long term thermal stability, and solvent resistance are required. It is anticipated that such polymers could find uses in future long duration exploration missions as well. Their use would be even more advantageous if self-healing capability or mechanisms could be incorporated into these polymers. Such innovative approaches are currently being studied at the NASA Kennedy Space Center for use in high performance wiring systems or inflatable and habitation structures. Self-healing or self-sealing capability would significantly reduce maintenance requirements, and increase the safety and reliability performance of the systems into which these polymers would be incorporated. Many unique challenges need to be overcome in order to incorporate a self-healing mechanism into flexible, high performance polymers. Significant research into the incorporation of a self-healing mechanism into structural composites has been carried out over the past decade by a number of groups, notable among them being the University of I1linois [I]. Various mechanisms for the introduction of self-healing have been investigated. Examples of these are: 1) Microcapsule-based healant delivery. 2) Vascular network delivery. 3) Damage induced triggering of latent substrate properties. Successful self-healing has been demonstrated in structural epoxy systems with almost complete reestablishment of composite strength being achieved through the use of microcapsulation technology. However, the incorporation of a self-healing mechanism into a system in which the material is flexible, or a thin film, is much more challenging. In the case of using microencapsulation, healant core content must be small enough to reside in films less than 0.1 millimeters thick, and must overcome significant capillary and surface tension forces to flow, mix and react to achieve healing. Vascular networks small enough to fit into such films must also overcome these same flow limitations. Self-healing has also been demonstrated in ionomeric substrates such as Surlyn , wherein the heat generated by a projectile impact triggers the latent ability of this substrate to flow back to its original shape. Recent work using Diels-Alder reactions have shown promise in bringing about actual reforming of broken chemical bonds to achieve self-healing [2]. All self-healing mechanisms that rely on the use of inherent latent substrate properties require some degree of polymer chain flow to achieve any significant level of healing.

Jolley, Scott T.↗